Multi-stage fuel pump

ABSTRACT

A multi-stage fuel pump has a drive assembly, a pump assembly including first and second pumping elements disposed between various plates of the pump assembly, and first and second pumping channels each having an inlet and an outlet circumferentially offset from the inlet and the outlet of the other pumping channel. Desirably, the pumping channels are offset to control or orient the forces acting on the drive assembly, pumping elements and the plates of the pump assembly, including radial, axial and torsional forces.

FIELD OF THE INVENTION

[0001] The present invention relates generally to fuel delivery systemsand more particularly, to a fuel pump.

BACKGROUND OF THE INVENTION

[0002] Electric motor fuel pumps have been widely used to supply thefuel demand of an operating engine, such as in automotive applications.These pumps may be mounted directly within a fuel supply tank and havean inlet through which fuel from the tank is drawn into the fuel pumpand an outlet through which fuel is discharged under pressure fordelivery to the engine. The electric motor in the pump typicallyincludes a rotor mounted for rotation about its axis in a housing inresponse to application of electrical power to the motor. In so-calledturbine-type fuel pumps, the motor drives an impeller for rotation toincrease the pressure of fuel and deliver it to the engine. One exampleof a turbine-type fuel pump is illustrated in U.S. Pat. No. 5,257,916.

[0003] In general, it may be desirable to reduce leakage in the pumpassembly to improve the efficiency of the pump. However, reducingleakage generally requires manufacturing the pump to tighter or smallertolerances and that leads to increased costs and difficulties inmanufacturing the pump assembly. For example, a typical pump assemblyhas an impeller with opposed generally planar faces disposed between twoplates each having a generally planar face adjacent to the impeller. Toreduce leakage between the impeller and the plates, the clearancebetween their adjacent faces must be made small. However, reducing theclearance between the plates and the impeller can unduly increase thefriction between them and thereby affect the performance of the fuelpump. Accordingly, various methods have been employed to control therelative spacing between the impeller and the plates including lappingof one or more of the planar surfaces to insure compliance with stricttolerances, and grinding of the periphery of the impeller or otheradjacent surfaces to insure their size and shape are within the closelyheld tolerances.

[0004] An additional factor to be considered in the manufacture andassembly of the fuel pump assembly is that the pressure of the fuelbetween the inlet and outlet of the pumping assembly is varied. At theinlet, the pressure may be at or below atmospheric pressure, while atthe outlet the pressure may be substantially above atmospheric pressureand, for example, on the order of 40-80 psi or higher. Accordingly, theforces acting on the impeller and the rest of the pumping assembly varygreatly as a function of the pressure of fuel in the various regions ofthe pumping assembly. The varied forces across the impeller and thepumping assembly as a whole produce side loading and torque on a shaftthat drives the impeller as well as a tendency to displace the pumpingelements and adjacent plates thereby increasing friction between them.These conditions also occur in so-called two stage fuel pumps that havetwo pumping elements arranged in series.

SUMMARY OF THE INVENTION

[0005] A multi-stage fuel pump has a drive assembly, a pump assemblyincluding first and second pumping elements disposed between variousplates of the pump assembly, and first and second pumping channels eachhaving an inlet and an outlet circumferentially offset from the inletand the outlet of the other pumping channel. Desirably, the pumpingchannels are offset to control or orient the forces acting on the driveassembly, pumping elements and the plates of the pump assembly,including radial, axial and torsional forces.

[0006] Typically, the drive assembly includes an electric motor thatdrives the pumping elements for rotation between the plates via a shaftconnected to the pumping elements. The varying pressure in the pumpingchannels, from the low pressure at the inlet to a higher pressure at theoutlet, produces radial or side loading on the shaft which can affectthe efficiency of the fuel pump. Accordingly, circumferentiallyoffsetting the first and second pumping channels can help to offset theside loading on the shaft, in addition to offsetting the forces actingon the pumping elements and plates, to increase the efficiency of thefuel pump.

[0007] Some objects, features and advantages of the invention includeproviding a fuel pump that has improved bearing durability, can beutilized in higher pressure fuel systems, can be manufactured andassembled at reduced cost, can be manufactured with larger tolerances,can utilize a less expensive motor shaft, is of relatively simpledesign, has improved efficiency, and has a long, useful life in service.Of course, other objects, features and advantages will be apparent tothose skilled in the art in view of this disclosure. And fuel pumpsembodying the invention may achieve more or less than the noted objects,features or advantages.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] These and other objects, features and advantages of the presentinvention will be apparent from the following detailed description ofthe preferred embodiments, appended claims and accompanying drawings inwhich:

[0009]FIG. 1 is a cross-sectional view of a fuel pump according to afirst embodiment of the invention;

[0010]FIG. 2 is a top view of an upper plate of the fuel pump of FIG. 1;

[0011]FIG. 3 is a cross-sectional view taken generally along line 3-3 inFIG. 2;

[0012]FIG. 4 is a bottom view of the upper plate;

[0013]FIG. 5 is a cross-sectional view taken generally along line 5-5 inFIG. 2;

[0014]FIG. 6 is a plan view of a guide ring;

[0015]FIG. 7 is a cross-sectional view taken generally along line 7-7 inFIG. 6;

[0016]FIG. 8 is a plan view of an impeller of the fuel pump in FIG. 1;

[0017]FIG. 9 is a cross-sectional view taken generally along line 9-9 inFIG. 8;

[0018]FIG. 10 is a cross-sectional view taken generally along line 10-10in FIG. 8;

[0019]FIG. 11 is a side view of an intermediate plate of the fuel pumpof FIG. 1;

[0020]FIG. 12 is a bottom view of the intermediate plate;

[0021]FIG. 13 is a top view of the intermediate plate;

[0022]FIG. 14 is a side view of a lower plate of the fuel pump of FIG.1;

[0023]FIG. 15 is a bottom view of the lower plate;

[0024]FIG. 16 is a top view of the lower plate;

[0025]FIG. 17 is a cross-sectional view taken generally along line 17-17in FIG. 15;

[0026]FIG. 18 is a bottom view of an intermediate plate of a fuel pumpaccording to an alternate embodiment; and

[0027]FIG. 19 is a top view of the intermediate plate of FIG. 18.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] Referring in more detail to the drawings, FIGS. 1-17 illustrate amulti-stage fuel pump, shown here as a two-stage fuel pump 20, accordingto one embodiment of the present invention. As best shown in FIG. 1, thefuel pump 20 has a pump assembly 22 with a first stage impeller 24 whichincreases the pressure of fuel and delivers it to a second stageimpeller 26 which further increases the pressure of fuel beforedischarging it for delivery to an engine. The first and second impellers24, 26 define at least in part first and second fuel pumping channels,28, 30 respectively. The second fuel pumping channel 30 iscircumferentially offset from the first pumping channel 28 to at leastpartially offset the reaction forces caused by the pressurized fuelwithin the pump assembly 22 of the fuel pump 20.

[0029] The fuel pump 20 has a housing with an outer shell 34 that has apair of open ends one of which receives an outlet end cap 36 containingan outlet 38 of the fuel pump 20. The other end of the shell 34 ispreferably rolled around a circumferential shoulder 40 of a lower plate42 of the pump assembly 22. Received in the housing is a drive assembly32 that has an electric motor with a rotor 44 journalled by a shaft 46for rotation within a permanent magnet stator 48 received within a fluxtube 50. The rotor 44 is coupled to the first and second impellers 24,26 by the shaft 46 and a clip assembly 52. As shown, the clip assembly52 has a first portion 53 coupled to the shaft 46 and the secondimpeller 26 to drive the second impeller 26. The shaft 46 may have anon-circular periphery and a through hole in the first portion 53 isadapted so that the first portion 53 engages the non-circular shaft sothat the first portion 53 rotates with the shaft 46. A second portion 55of the clip assembly 52 is coupled to the first impeller 24 and thefirst portion 53 of the clip assembly 52 to drive the first impeller 24as the shaft 46 rotates. Of course, the impellers may be coupled to theshaft in other ways, with or without a clip or clip assembly.

[0030] The pump assembly 22 has the lower plate 42, the first impeller24, an intermediate plate 54, the second impeller 26 and an upper plate56. Preferably, guide rings 58, 60 are disposed each surrounding one ofthe first and second impellers 24, 26, respectively, with one guide ring58 between the lower plate 42 and intermediate plate 54 and the otherguide ring 60 between the intermediate plate 54 and upper plate 56.Thus, as shown, the first pumping channel 28 is defined between thelower plate 42, intermediate plate 54, guide ring 58 and first impeller24. The second pumping channel 30 is defined between the intermediateplate 54, upper plate 56, guide ring 60 and second impeller 26.

[0031] As shown in FIGS. 2-5, the upper plate 56 has a central throughhole 62 in which a bearing 64 is received to journal the shaft 46. Thebearing may be integrally formed with the upper plate 56, or may be aseparate piece fitted into the hole 62. A radially outwardly extendingflange 66 and an annular upstanding wall 68 receive the lower end of theflux tube 50 in assembly. The upper plate 56 preferably has a generallyplanar lower surface 70 disposed adjacent to the second impeller 26 andthe guide ring 60 in assembly. An arcuate groove 72 formed in the lowersurface 70 defines in part the second pumping channel 30. One end 74 ofthe arcuate groove 72 is disposed adjacent to the inlet of the secondpumping channel 30 and the other end 76 of the groove 72 is disposedadjacent to the outlet of the second pumping channel 30. A plurality ofgenerally axially extending and circumferentially spaced recesses 78 maybe formed in the lower surface 70 opening into the groove 72 at one endand extending radially inwardly from the groove 72. These recesses 78may be constructed as disclosed in U.S. Pat. No. 5,257,916; thedisclosure of which is incorporated herein by reference in its entirety.An opening 79 through the upper plate 56 communicates the outlet of thesecond pumping channel with the interior of the housing downstream ofthe pump assembly 22.

[0032] The guide rings 58, 60 of the pump assembly 22 are shown in FIGS.6 and 7. Both guide rings 58, 60 may be of identical construction. Asshown, the guide rings 58, 60 are annular and of a predeterminedthickness to control the spacing between the adjacent plates to permitrotation of the impellers 24, 26 between the plates. Each guide ring 58,60 surrounds its respective impeller 24, 26 and preferably has aradially inwardly extending rib 80 disposed generally midway betweenopposed planar faces 82, 84 of the guide ring.

[0033] As shown in FIGS. 8-10, the first and second impellers 24, 26 maybe of identical construction. In the form shown, the impellers 24, 26are generally flat circular disks with a plurality of generally radiallyextending vanes 86 about their periphery. The vanes 86 define pockets 88in which fuel in the respective pumping channels is received, androtation of the impellers thereby moves fuel through the pumpingchannels. The impellers 24, 26 also have a central through hole 90 whichreceives the shaft 46 and preferably one or more radially spacedopenings 92 which receive drive members or fingers 94 of the clipassembly 52 that couples the impellers to the shaft. Alternatively, forexample without limitation, the impellers 24, 26 may have a non-circularcentral hole complementary to a non-circular shaft to couple theimpellers to the shaft. As shown, the impellers 24, 26 have one or moreopenings 92 radially spaced from the central hole 90 with each suchopening 92 adapted to receive a separate finger 94 (FIG. 1) of the clipassembly 52. The impellers 24, 26 can be formed in substantially anymanner, and may have vanes constructed and arranged differently fromthat shown. For example, without limitation, the vanes may be disposedinwardly from the periphery of the impeller, the vanes may be formed sothat the pockets are open to only one face of the impeller, and theimpellers 24, 26 may be of different construction with different vanetypes or arrangements.

[0034] As shown in FIGS. 11-13, the intermediate plate 54 is preferablya generally flat circular disk with opposed, planar upper and lowerfaces 96, 98. The upper face 96 is disposed adjacent to the guide ring60 and the second impeller 26 and the lower face 98 is disposed adjacentto the guide ring 58 and the first impeller 24. As shown in FIG. 13, anarcuate groove 100 is preferably formed in the upper face 96 of theintermediate plate 54 to define in part the second pumping channel 30.The arcuate groove 100 preferably has one end 102 generally adjacent tothe inlet of the second pumping channel 30 and another end 104 generallyadjacent to the outlet of the second pumping channel 30. A transitionalgroove portion 106 leads from the end 102 of the groove 100 adjacent tothe inlet of the second pumping channel 30 to a hole 108 extendingthrough the intermediate plate 54. In this manner, the hole 108 iscommunicated with the second pumping channel 30 via the transitionalportion 106 and the arcuate groove 100 in the upper surface 96 of theintermediate plate 54. Generally axially extending and circumferentiallyspaced recesses 110 may be formed adjacent to the arcuate groove 100, asgenerally described with reference to the upper plate 56. A central hole112 through the intermediate plate 54 receives the shaft 46 andassociated portions of the clip assembly 52.

[0035] As best shown in FIG. 12, in the lower surface 98 of theintermediate plate 54, a second arcuate groove 114 is formed whichdefines in part the first pumping channel 28. The second arcuate groove114 has one end 116 generally adjacent to the inlet of the first pumpingchannel 28 and another end 118 generally adjacent to the outlet of thefirst pumping channel 28. A transitional groove portion 120 extends fromthe end 118 of the second arcuate groove 114 that is adjacent to theoutlet of the first pumping channel 28 to the hole 108 through theintermediate plate 54. Accordingly, the hole 108 is communicated withthe first pumping channel 28 via the transitional portion 120 and thesecond arcuate groove 114 in the lower surface 98 of the intermediateplate 54. A plurality of radially extending and circumferentially spacedrecesses 122 may be formed in the lower surface 98 of the intermediateplate 54 as described with reference to the upper surface 96.

[0036] As shown in FIGS. 14-17, the lower plate 42 has an opening 128defining an inlet 130 of the fuel pump 20 through which fuel is receivedfrom a fuel tank. A blind bore 132 in the lower plate 42 receives theend of the shaft 46 and may having a bearing disposed therein, such as aball bearing or other bearing surface. The lower plate 42 preferably hasa generally planar upper surface 134 adjacent to which the guide ring 58and first impeller 24 are received in assembly. A generally arcuategroove 136 is formed in the upper surface 134 of the lower plate 42 todefine in part the first pumping channel 28. The arcuate groove 136preferably has one end 138 generally adjacent to inlet 130 of the firstpumping channel 28 and another end 140 generally adjacent to the outletof the first pumping channel 28. Axially extending and circumferentiallyspaced recesses 142 may be formed in the upper surface 134 of the lowerplate 42 as discussed with reference to the other plates.

[0037] Accordingly, as shown in FIGS. 1-17 the first pumping channel 28is defined by the arcuate groove 136 in the lower plate 42, the guidering 58, the first impeller 28, and the arcuate groove 114 formed in thelower face 98 of the intermediate plate 54. An inlet 144 of the firstpumping channel 28 is defined generally in the area of the end 138 ofgroove 136 and the end 116 of groove 114. An outlet 146 of the firstpumping channel 28 is defined generally in the area of the end 140 ofthe groove 136 and the end 118 of the groove 114. Similarly, the secondpumping channel 30 is defined by the arcuate groove 100 formed in theupper face 96 of the intermediate plate 54, the guide ring 60, thesecond impeller 26, and the groove 72 formed in the upper plate 56. Aninlet 148 of the second pumping channel 30 is defined generally in thearea of the end 102 of groove 100 and the end 74 of groove 72. An outlet150 of the second pumping channel 30 is defined generally in the area ofthe end 104 of groove 100 and the end 76 of groove 72. Preferably, eachpumping channel spans an angle of less than 360°, and preferably morethan 300°.

[0038] As shown, the second fuel pumping channel 30 is circumferentiallyoffset from the first fuel pumping channel 28. Desirably, the inlet 148of the second pumping channel 30 is offset from the inlet 144 of thefirst pumping channel 28 by between about 60°-240°, and preferablybetween 150°-210°. Likewise, the outlet 150 of the second pumpingchannel 30 is desirably offset from the outlet 146 of the first pumpingchannel 28 by between about 60°-240°, and preferably between 150°-210°.Because the second fuel pumping channel 30 is circumferentially offsetfrom the first fuel pumping channel 28, the transition portions 106 and120 formed in the intermediate plate 54 are constructed and arranged tocommunicate the outlet 146 of the first pumping channel 28 with theinlet 148 of the second pumping channel 30 via the hole 108 in theintermediate plate 54.

[0039] Thus, the first pumping channel 28 and second pumping channel 30are arranged in series. Fuel enters the pumping assembly via the fuelinlet 130 which leads to the inlet 144 of the first pumping channel 28,fuel is then moved to the outlet 146 of the first pumping channel 28,through the intermediate plate 54, into the inlet 148 of the secondpumping channel 30 and then finally out of the outlet 150 of the secondpumping channel 30 where it flows up through the fuel pump housing 32and ultimately out of the fuel pump outlet 38. As shown, the first andsecond fuel pumping channels 28, 30 are formed adjacent to the peripheryof the plates 42, 54, 56 and the first and second impellers 24, 26, andthe hole 108 through the intermediate plate 54 is disposed radiallyinwardly of the pumping channels 28, 30.

[0040] As shown in FIGS. 18-19, a fuel pump according to a secondembodiment of the present invention has an intermediate plate 200 withan arcuate groove 204 in its lower surface 206, shown in FIG. 18, thatdefines in part the first fuel pumping channel 28. An arcuate groove 208in the upper surface 210 of the intermediate plate 200, shown in FIG.19, defines in part the second fuel pumping channel 30. To communicatethe outlet 146 of the first pumping channel 28 with the inlet 148 of thesecond pumping channel 30, a passage 212 extends through theintermediate plate 200. The passage 212 communicates one end 214 of thearcuate groove 204 in the lower surface 206 that is adjacent to theoutlet 146 of the first pumping channel 28 with one end 216 of thearcuate groove 208 in the upper surface 210 that is in the area of theinlet 148 of the second pumping channel 30. Of course, many otherarrangements of grooves and/or passages in, through and around theintermediate plate may be employed to communicate the first pumpingchannel 28 with the second pumping channel 30.

[0041] In each embodiment of the fuel pump, the first pumping channel 28and second pumping channel 30 are circumferentially offset. Desirably,the offset fuel pumping channels can offset or balance at least to someextent the forces acting on the fuel pump assembly 22 due to the varyingpressure of fuel within the pump assembly 22. For example, fuel at anoutlet of a pumping channel is at a much greater pressure then fuel atthe inlet of that pumping channel. Hence, a side load and torque isexperienced in the pump assembly 22 components, including the shaft 46which drives the impellers 24, 26. With the specific embodimentsdisclosed, the radial or side load forces acting on the shaft 46 throughthe impellers 24, 26 can be oriented in a manner in which the force fromone impeller at least partially offsets the force from the otherimpeller. The torsional forces on the impellers can be arranged so thatthey compliment each other and preferably tend to rotate the impellersand shaft in the same direction of rotation as the rotor 48 of theelectric motor.

[0042] As viewed in FIG. 18, the net side load force in the firstpumping channel 28 would act from the left to the right across theintermediate plate as shown from the outlet side 146 toward the inletside 144. In FIG. 19, the net side load force in the second pumpingchannel acts from the right to the left across the intermediate plate asshown (from the outlet side 150 towards the inlet side 148). Hence,relative to the shaft, these side load forces tend to offset each other,at least in part. Desirably, this may permit use of a shaft of reducedstrength or hardness due to the reduction of the side or radial forceson the shaft. Further, due at least in part to the reduced net axialforces in the fuel pump assembly, the pumping elements can bemanufactured with larger tolerances and potentially without requiringsecondary machining operations such as lapping or grinding.

[0043] Persons of ordinary skilled in the art will readily recognizethat the preceding description of the preferred embodiments of thepresent invention is illustrative of the present invention rather thanlimiting. Alterations and modifications may be made to the variouselements of the fuel pump without departing from the spirit and scope ofthe present invention. For example, and without limitation, the pumpingelements may be constructed in a manner other than specificallydisclosed, and the plates may have peripheral rims or other structuresthat obviate the need for a separate guide ring surrounding the pumpingelements. Again, other modifications may also be made within the spiritand scope of the present invention.

What is claimed is:
 1. A fuel pump, comprising: a drive assembly; a pumpassembly having a lower plate, an intermediate plate, an upper plate, afirst pumping element disposed between the lower plate and theintermediate plate and driven for rotation by the drive assembly, and asecond pumping element disposed between the intermediate plate and theupper plate and driven for rotation by the drive assembly; a firstpumping channel defined at least in part by the first pumping element,having an inlet through which fuel is received at a first pressure andan outlet through which fuel is discharged at a second pressure higherthan the first pressure; and a second pumping channel defined at leastin part by the second pumping element, having an inlet through whichfuel is received generally at the second pressure and an outlet throughwhich fuel is discharged at a third pressure higher than the secondpressure, wherein the inlet of the second pumping channel iscircumferentially offset from the inlet of the first pumping channel,and the outlet of the second pumping channel is circumferentially offsetfrom the outlet of the first pumping channel.
 2. The fuel pump of claim1 wherein the first pumping channel inlet is offset from the secondpumping channel inlet by between 60 and 240 degrees.
 3. The fuel pump ofclaim 1 wherein the first pumping channel inlet is offset from thesecond pumping channel inlet by between 150 and 210 degrees.
 4. The fuelpump of claim 1 wherein the first pumping channel outlet is offset fromthe second pumping channel outlet by between 60 and 240 degrees.
 5. Thefuel pump of claim 1 wherein the first pumping channel outlet is offsetfrom the second pumping channel outlet by between 150 and 210 degrees.6. The fuel pump of claim 1 wherein the first and second pumpingchannels are defined at least in part by arcuate grooves defined in thepump assembly, and the first and second pumping channels each span anangle of over 300 degrees between their respective inlets and outlets.7. The fuel pump of claim 1 wherein the intermediate plate has a throughhole communicating the first pumping channel and the second pumpingchannel.
 8. The fuel pump of claim 7 wherein the through holecommunicates with the outlet of the first pumping channel and the inletof the second pumping channel.
 9. The fuel pump of claim 7 wherein theintermediate plate has a generally planar lower surface with an arcuategroove formed in its lower surface to define at least in part the firstpumping channel, the groove in the lower surface of the intermediateplate spans from the inlet of the first pumping channel to the outlet ofthe first pumping channel, and has a transition portion extending fromthe region of the outlet of the first pumping channel to the throughhole.
 10. The fuel pump of claim 9 wherein the through hole of theintermediate plate is disposed radially inwardly from the first pumpingchannel.
 11. The fuel pump of claim 7 wherein the intermediate plate hasa generally planar upper surface with an arcuate groove formed in theupper surface to define at least in part the second pumping channel, thegroove in the upper surface of the intermediate plate spans from theinlet of the second pumping channel to the outlet of the second pumpingchannel, and has a transition portion extending from the region of theinlet of the second pumping channel to the through hole.
 12. The fuelpump of claim 11 wherein the through hole of the intermediate plate isdisposed radially inwardly from the second pumping channel.
 13. The fuelpump of claim 1 wherein at least one of the first pumping element andthe second pumping element is an impeller having a plurality ofcircumferentially spaced vanes disposed generally adjacent to theperiphery of the impeller.
 14. The fuel pump of claim 13 wherein thevanes extend generally radially outwardly about the periphery of theimpeller.
 15. The fuel pump of claim 14 wherein both the first pumpingelement and second pumping elements are impellers.